Solar retrofit lighting system

BACKGROUND OF THE INVENTION

p-0002This invention relates to the retrofitting of both functioning and non-functioning outdoor light poles with solar power to replace or supplement the conventional power supply from the “grid.” More particularly, the invention relates to the use of solar laminate film affixed to at least (2) two semi-circular aluminum lightweight panels, which will attach to adjustable internal mounting brackets. These panels will be affixed to any dimension, diameter, or finish. This will be applicable with any existing pole without compromising the integrity of the existing pole.

p-0003The use of solar power for street lights has been attempted in the past and most attempts involve the use of flat rectangular solar panels mounted atop the light pole. This type of application is prone to failure, particularly in areas subjected to high winds such as experienced in hurricanes. A more recent attempt as shown in Myer, U.S. Pat. No. 7,731,383 shows a self-contained solar powered light pole fabricated with flexible solar laminate film attached to the outer surface of the pole wall itself. In the Myer '383 invention, the pole itself is a new installation with cooling vents and is installed as a new light pole with attendant cost. In Myer, U.S. Pat. No. 8,029,154, a continuation of the Myer '383 patent, flexible solar laminate film is adhesively connected to the outside surface of a light pole.

p-0004Unfortunately, installation of an entirely new pole, whether solar powered or not, is not always possible because of the financial shortfalls facing most municipalities and administrations that provide public lighting. In addition, most cities have a significant number of non-functioning or abandoned street lights and light poles. For example, administration officials in the City of New Orleans said in May of 2012, that of the 55,000 street lights in the city, more than 10,900 were not working. Tragic accidents have occurred where highways and streets are unlit and lined with inoperable light poles. In addition to general traffic safety concerns, a loss of conventional city power from the “grid” during a storm or natural disaster renders all street lighting useless at a time when it is needed the most.

p-0005Likewise, the concept of adhesively attaching flexible solar laminate film to an existing pole is impractical and limited in that there are many versions of light pole with different cross sections, some being cylindrical, and some being octagonal. Other light poles are roughly cylindrical but have a rough hewn outer surface as in the ubiquitous timber pole. Obviously, many of existing light poles do not have an outer surface suitable for adhesive attachment of flexible solar laminate film directly to the outer surface.

p-0006There is a definite need for a reliable system to retrofit all types of existing light poles with a solar power system that would operate during power outages, supplement the grid”, and also provide lighting and power to abandoned light poles. Likewise, there is a need for a solar powered lighting system for light poles that can sustain a storm event without damage.

SUMMARY OF THE INVENTION

p-0007It is an object of the invention to provide a solar retrofit lighting system for light poles having a vertical longitudinal axis comprising at least two semi-circular rigid longitudinal panels mounted along the exterior surface of an existing light pole where the panels would have a concave inner surface and a convex outer surface with the inner surface facing the exterior surface of the light pole but with a space between the concave inner surface and the exterior surface of the light pole, and a thin film photovoltaic laminate adhesively attached to the convex outer surface. The semi-circular rigid longitudinal panels would be mounted in parallel with the longitudinal axis of the light pole with spacer bolts, nuts and washers, and the spacer bolts holding the panels away from the light pole at a distance sufficient to create a space allowing for air circulation.

p-0008It is a further object of this invention to provide a solar array panel assembly for installation on existing light poles both powered and not powered, with solar array pole frames, solar array backing panels having a curved cross section describing a portion of a circle with an outer convex side and an inner concave side having thin film photovoltaic laminate adhesively attached, where the solar array pole frames support the solar array backing panels on the inner concave side of the backing panels, and where the solar array pole frames are adjustable to various sizes and configurations of light poles, and further to provide end caps at both ends of the solar array panel assembly. The present invention would further comprise a battery (located at the top of the existing pole) for storage of electrical energy from the thin film photovoltaic laminate, a charge controller to regulate the charging of the battery, an inverter to convert DC to AC power and an LED light fixture extending from the pole. Alternatively, an on-grid option will be utilized where as a grid tied inverter will be place at the pole location, converted and sent through utility lines back to the grid. Inversely, we will draw power from the grid which will be commercially metered as needed for hours when sunlight is unavailable.

p-0009It is a further object of this invention to provide a method for providing a solar retrofit lighting system for light poles with a vertical longitudinal axis, an external surface, an upper end and a lower end, the method including: a) providing a solar array panel assembly having an upper end and a lower end with an upper end cap and a lower end cap, with more than one semi-circular backing panels having an upper and lower end, having an outer convex surface and an inner concave surface with thin film photovoltaic laminate adhesively attached to the outer convex surface, said panel assembly to be mounted in parallel with the longitudinal axis of the light pole, and said panel assembly to be supported on the inner concave surface by a plurality of pole frames to be mounted to the external surface of the light pole, a battery for storage of electrical energy from the thin film photovoltaic laminate, a controller to regulate charging of the battery, an inverter to convert DC power to AC power; and an LED light fixture; b) mounting the plurality of pole frames to the external surface of the light pole; c) mounting the backing panels on the plurality of pole frames in parallel with the longitudinal axis of the light pole; d) installing end caps at the upper and lower ends of the backing panels and cutting the opening to fit the light pole; e) installing the battery, controller and inverter to receive electrical energy from the thin film photovoltaic laminate; f) installing an LED light fixture at or near the upper end of the light pole; and g) providing a grid-tied inverter to convert and send power into a power grid and draw power from the power grid as needed and installing the grid-tied inverter.

BRIEF DESCRIPTION OF THE DRAWINGS

p-0010<figref idrefs="DRAWINGS">FIG. 1</figref> is an elevation of the solar retrofit lighting system installed on a light pole.

p-0011<figref idrefs="DRAWINGS">FIG. 2</figref> is a perspective view of the solar array panel assembly.

p-0012<figref idrefs="DRAWINGS">FIG. 3</figref> is an exploded perspective view of the thin film photovoltaic laminate superimposed over a solar array backing panel.

p-0013<figref idrefs="DRAWINGS">FIG. 4</figref> is a longitudinal cross section of the solar array panel assembly showing a plurality of solar array panel assembly pole frames.

p-0014<figref idrefs="DRAWINGS">FIG. 5</figref> is a side elevation of a solar array panel assembly pole frame within the solar array panel assembly.

p-0015<figref idrefs="DRAWINGS">FIG. 6</figref> is an exploded view of a solar array panel assembly pole frame.

p-0016<figref idrefs="DRAWINGS">FIG. 7</figref> is a perspective view of a solar array panel assembly pole frame.

p-0017<figref idrefs="DRAWINGS">FIG. 8</figref> is an overhead view of a solar array panel assembly pole frame.

p-0018<figref idrefs="DRAWINGS">FIG. 9</figref> is a side elevation of a solar array panel assembly pole frame.

p-0019<figref idrefs="DRAWINGS">FIG. 10</figref> is an overhead view of a cover assembly.

DETAILED DESCRIPTION OF THE INVENTION

p-0020The elevation depicted in <figref idrefs="DRAWINGS">FIG. 1</figref> shows the inventive solar retrofit lighting system <b>1</b> installed on a light pole <b>2</b> with an LED light fixture <b>3</b> on a support <b>4</b>. Mounted out from the outer surface <b>6</b> of the light pole <b>2</b> is a solar array panel assembly <b>10</b> for collection of solar energy and generation of electricity. The electricity generated from the solar array panel assembly will be conducted to a module <b>7</b> and through an inverter to convert DC to AC power with a storage battery <b>8</b> and a controller <b>9</b> to regulate the charging of the battery that will in turn provide power to the LED light fixture <b>3</b> extending from the light pole <b>2</b> during darkness or supplement electrical power to those poles on the “grid”. Alternatively, an on-grid option will be utilized where as a grid tied inverter will be place at the pole location, converted and sent through utility lines back to the grid. Inversely, we will draw power from the grid which will be commercially metered as needed for hours when sunlight is unavailable.

p-0021<figref idrefs="DRAWINGS">FIG. 2</figref> shows a perspective view of a solar array panel assembly <b>10</b> with an upper end <b>10</b><i>a </i>and a lower end <b>10</b><i>b </i>and a cover assembly <b>13</b> at both upper and lower ends <b>10</b><i>a </i>and <b>10</b><i>b </i>although only the cover assembly <b>13</b> at the upper end <b>10</b><i>a </i>can be seen in <figref idrefs="DRAWINGS">FIG. 2</figref>. On the exterior side <b>10</b><i>c </i>of the solar array panel assembly <b>10</b> are backing panels <b>11</b> having a curved cross section describing a portion of a circle with an outer convex side <b>11</b><i>a </i>and an inner concave side <b>11</b><i>b </i>not seen in <figref idrefs="DRAWINGS">FIG. 2</figref>. On the outer convex side <b>11</b><i>a </i>of the backing panels <b>11</b> is adhesively attached thin film photovoltaic laminate <b>5</b>. A lightweight yet rigid material such as aluminum would be suitable for the backing panels <b>11</b>.

p-0022<figref idrefs="DRAWINGS">FIG. 3</figref> show an exploded perspective view of the thin film photovoltaic laminate <b>5</b> superimposed over the outer convex side <b>11</b><i>a </i>of a solar array backing panel <b>11</b>. It is understood that there may be more than one solar array backing panel <b>11</b> on the solar array panel assembly <b>10</b>, and thin film photovoltaic laminate <b>5</b> is adhesively attached to the outer convex side <b>11</b><i>a </i>of at least one solar array backing panel <b>11</b>.

p-0023<figref idrefs="DRAWINGS">FIG. 4</figref> depicts a longitudinal cross section of the solar array panel assembly <b>10</b> with the upper end <b>10</b><i>a</i>, the lower end <b>10</b><i>b</i>, and the interior side <b>10</b><i>d </i>that would correspond to the inner concave sides <b>11</b><i>b </i>of the solar array backing panels <b>11</b>. Within the interior of the solar array panel assembly <b>10</b> and between the interior sides <b>10</b><i>d </i>are shown a plurality of solar array panel assembly adjustable internal mounting brackets hereinafter referred to as pole frames <b>12</b>, also shown in greater detail in <figref idrefs="DRAWINGS">FIG. 5</figref>. At both the upper end <b>10</b><i>a </i>and the lower end <b>10</b><i>b </i>of the solar array panel assembly <b>10</b> are shown cover assemblies <b>13</b>.

p-0024In <figref idrefs="DRAWINGS">FIGS. 6</figref>, <b>7</b>, <b>8</b> and <b>9</b> are shown respectively an exploded view, a perspective view, an overhead view and a side elevation of a solar array panel assembly pole frame <b>12</b>. As shown the pole frame <b>12</b> has pole frame bands <b>14</b> with pole band plates <b>18</b>, pole band ring plates <b>19</b>, pole frame connection plates <b>15</b>, ring lugs <b>17</b>, and pole frame connection linkages <b>16</b>. Each of the pole frame connection linkages <b>16</b> has a linkage <b>20</b>, a diagonal linkage <b>21</b>, a brace <b>22</b>, and linkage lugs <b>23</b>. As shown, the linkage members will have suitable pin connections. A light weight rigid material such as aluminum would be suitable for manufacture of the pole frames <b>12</b>.

p-0025As shown the pole frame bands <b>14</b> describe a semi-circular arc of a radius matching the curvature of the inner concave side <b>11</b><i>b </i>of the solar array backing panels <b>11</b>. The pole frame bands <b>14</b> have a pole band plate <b>18</b> with an outer surface <b>18</b><i>a </i>and an inner surface <b>18</b><i>b</i>, and a pole band ring plate <b>19</b> with an outer edge <b>19</b><i>a </i>and an inner edge <b>19</b><i>b</i>, as well as an upper surface <b>19</b><i>c </i>and a lower surface <b>19</b><i>d</i>. The inner surface <b>18</b><i>b </i>of the pole band plate <b>18</b> is fixedly attached to the outer edge <b>19</b><i>a </i>of the pole band ring plate <b>19</b>. The outer surface <b>18</b><i>a </i>of the pole band plate <b>18</b> will directly contact the inner concave side <b>11</b><i>b </i>of the solar array backing panels <b>11</b> when the solar array panel assembly <b>10</b> is complete and installed on a light pole <b>2</b>. Each semi-circular pole frame band <b>14</b> has a right end <b>14</b><i>a </i>and left end <b>14</b><i>b</i>. The right end <b>14</b><i>a </i>of one pole frame band <b>14</b> will be attached to the left end of another pole frame band <b>14</b> and the left end of the first pole frame band <b>14</b> will be attached to the right end of the second pole frame band <b>14</b> to form a complete circle. This attachment will be accomplished with connection plates <b>15</b> bolted or otherwise attached to the upper or lower surfaces <b>19</b><i>c </i>and <b>19</b><i>d </i>of the pole band ring plates <b>19</b> at the of the right end <b>14</b><i>a </i>and left end <b>14</b><i>b </i>of connecting pole frame bands <b>14</b>. It is understood that the connection of pole frame bands <b>14</b> will be accomplished around a light pole <b>2</b> in conjunction with the installation of the solar array panel assembly <b>10</b>.

p-0026On the upper or lower surfaces <b>19</b><i>c </i>and <b>19</b><i>d </i>of the pole band ring plates <b>19</b> will be rigidly attached at least one ring lug <b>17</b> with a circular aperture <b>17</b><i>a </i>for insertion of a pivot pin. Pivotally connected to each ring lug <b>17</b> at the circular aperture <b>17</b><i>a </i>will be a connection linkage <b>16</b> with a diagonal linkage <b>21</b>, a pole band brace <b>22</b>, linkage lugs <b>23</b> and a pole band linkage <b>20</b>. The diagonal linkage <b>21</b> has an upper end <b>21</b><i>a </i>and a lower end <b>21</b><i>b</i>. The upper end <b>21</b><i>a </i>will have a circular aperture <b>21</b><i>c </i>for insertion of a pivot pin and will be pivotally connected to the circular aperture <b>17</b><i>a </i>of a ring lug <b>17</b>. The lower end <b>21</b><i>b </i>likewise will have a circular aperture <b>21</b><i>d </i>for insertion of a pivot pin. In addition the diagonal linkage <b>21</b> will have an intermediate circular aperture <b>21</b><i>e </i>disposed between the upper end <b>21</b><i>a </i>and a lower end <b>21</b><i>b </i>for insertion of a pivot pin. The pole band brace <b>22</b> has an outer end <b>22</b><i>a </i>and an inner end <b>22</b><i>b </i>with circular apertures <b>22</b><i>c </i>and <b>22</b><i>d </i>respectively, each for insertion of a pivot pin. The pole band linkage <b>20</b> has an upper end <b>20</b><i>a </i>and a lower end <b>20</b><i>b</i>, an inner side <b>20</b><i>c </i>and an outer side <b>20</b><i>d</i>. On the inner side <b>20</b><i>c </i>at both the upper end <b>20</b><i>a </i>and a lower end <b>20</b><i>b </i>is affixed a linkage lug <b>23</b> with a circular aperture <b>23</b><i>a </i>for insertion of a pivot pin. The outer end <b>22</b><i>a </i>of the pole band brace <b>22</b> is pivotally connected to the intermediate circular aperture <b>21</b><i>e </i>of the diagonal linkage <b>21</b>, and the inner end <b>22</b><i>b </i>of the pole band brace is pivotally connected to the linkage lug <b>23</b> on the upper end <b>20</b><i>a </i>and inner side <b>20</b><i>c </i>of the pole band linkage <b>20</b>. The lower end <b>21</b><i>b </i>of the diagonal linkage <b>21</b> is pivotally connected to the linkage lug <b>23</b> at the lower end <b>20</b><i>b </i>and the inner side <b>20</b><i>c </i>of the pole band linkage <b>20</b>.

p-0027The outer side <b>20</b><i>d </i>of the pole band linkage will directly contact the outer surface <b>6</b> of the light pole <b>2</b>. More than one intermediate circular aperture <b>21</b><i>e </i>in the diagonal linkage <b>21</b> and more than one circular aperture <b>22</b><i>c </i>at the outer end <b>22</b><i>a </i>of the pole band brace <b>22</b> will be provided to allow for adjustment to suit variations in light pole configuration and diameter.

p-0028<figref idrefs="DRAWINGS">FIG. 10</figref> shows an end cap cover assembly <b>13</b> with a flanged end cap side <b>24</b> and a non flanged end cap side <b>25</b>. The assembly <b>13</b> will be installed at both the upper end <b>10</b><i>a </i>and a lower end <b>10</b><i>b </i>of the solar array panel assembly <b>10</b>. The end cap sides <b>24</b> and <b>25</b> will both have apertures <b>26</b> for cables and other service, in addition to an end cap opening <b>27</b> for the light pole <b>2</b>. It is understood that end cap opening <b>27</b> will be cut to fit the light pole <b>2</b>.

p-0029In practice, a plurality of solar array pole frames <b>12</b> will be installed on a light pole <b>2</b> made the subject of the inventive solar retrofit lighting system. As shown in <figref idrefs="DRAWINGS">FIG. 4</figref>, there will be one solar array pole frame <b>12</b> at both the upper end <b>10</b><i>a </i>and a lower end <b>10</b><i>b </i>of the solar array panel assembly <b>10</b>. Once the solar array pole frames <b>12</b> have been installed, solar array backing panels <b>11</b> with thin film photovoltaic laminate <b>5</b> adhesively attached to the outer convex side <b>11</b><i>a </i>of at least one solar array backing panel <b>11</b> will be mounted upon the installed solar array pole frames <b>12</b>. It is not intended that the thin film photovoltaic laminate <b>5</b> must be installed completely around the solar array panel assembly <b>10</b>, but will be placed in accordance with the power requirements and best solar placement.